Continuous Fiber Additive Manufacturing Machine
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Solution Overview
Problem
Current additive manufacturing methods lack the ability to effectively integrate structurally reinforcing continuous fibers into parts, limiting the mechanical properties and efficiency of the manufacturing process.
Innovation Solution
A machine and method for additive manufacturing that deposits matrix layers and continuous fiber layers, using energy sources to soften and embed fibers into the matrix, and pressure to ensure integration, controlled by a computer for automated fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If manual layering of prepregs is used to fabricate continuous fiber-reinforced parts, then fiber reinforcement can be achieved, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical layering process with an automated additive manufacturing system that uses computer-controlled deposition of matrix material and fiber reinforcement. This substitution eliminates the need for manual handling and layering of prepregs, reducing labor intensity and process complexity while maintaining fiber reinforcement capabilities
Solution Approach 2:
The invention changes the physical state and deposition parameters of the matrix material by applying energy sources (heat, ultrasound, or other energy forms) to the matrix layers during the additive manufacturing process. This allows the matrix material to be deposited in a controllable manner that facilitates subsequent fiber embedding, transforming the process from manual layering to automated controlled deposition
2Productivity
If additive manufacturing is used to deposit matrix layers, then manufacturing efficiency is improved, but the ability to integrate continuous fibers is lost
Solution Approach 1:
The patent merges two previously separate processes - additive manufacturing of matrix layers and fiber reinforcement - into a single integrated process. The continuous fibers are embedded into the deposited matrix layers during the same additive manufacturing operation, combining the efficiency of automated matrix deposition with the structural benefits of fiber reinforcement
Solution Approach 2:
The invention performs preliminary action by depositing matrix layers with specific properties (using energy sources to control the state of the matrix material) before fiber deposition, creating an optimized substrate that facilitates subsequent fiber embedding and integration during the continuous additive manufacturing process
3Manufacturing precision
If energy sources are applied to soften matrix layers for fiber embedding, then fiber integration is improved, but energy consumption increases
Solution Approach 1:
The patent employs periodic or localized application of energy sources rather than continuous heating of the entire workpiece. Energy is applied selectively to specific matrix layers or regions where fiber embedding is required, reducing overall energy consumption while maintaining sufficient thermal energy for proper fiber integration
Solution Approach 2:
The invention introduces intermediary energy sources (such as ultrasound or localized heating elements) that act as mediators between the matrix material and fiber reinforcement. These intermediaries enable efficient energy transfer and fiber embedding with reduced total energy input compared to conventional bulk heating methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of fiber-reinforced components with enhanced mechanical properties and structural resilience, leveraging the efficiency of additive manufacturing while incorporating continuous fibers for improved strength and rigidity.
Implementation Method 1
a first energy source configured to soften any of the plurality of matrix layers
Implementation Method 2
a second energy source configured to melt any of the plurality of the matrix layers
Implementation Method 3
a pressure source configured to press the fiber layer into a previously deposited matrix layer
Data Source
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AI summary
A machine for fabricating a fiber-reinforced component by additive manufacturing is disclosed. The machine may have a surface, a matrix feed configured to deposit a plurality of matrix layers on the surface, and a fiber feed configured to deposit a fiber layer on at least one of the plurality of matrix layers. The deposition of the plurality of matrix layers and the fiber layer may be controlled by a computer.